Electrical plug contact

ABSTRACT

A plug connector element having a plurality of contact arms which are configured to permit the longitudinal edges thereof to abut upon total compression of the plug connector, such as when associated within a complimentary socket element, thus providing a relatively stable connection. The plug connector element is further provided with a sleeve or ferrule portion which is connected to the contact arms as well as to an associated conductor wire in such a manner as to assure penetrating engagement with the conductor wire while maintaining continuous contact between the contact arms and the conductor wire.

United States Patent Achten [541 ELECTRICAL PLUG CONTACT [72] Inventor:Kurt Joseph Achten, Granada Hill,

Calif.

[73] Assignee: Illinois Tool Works Inc., Chicago,

[22] Filed: Jan. 4, 1971 [21] Appl. No.: 103,464

[52] US. Cl. ..339/95 R, 339/252 P, 339/276 T [51] Int. Cl. ..l-I0lrll/20, HOlf 13/06 [58] Field of Search ..339/95, 252, 276

[56] References Cited UNlTED STATES PATENTS 3,252,127 5/1966 Woodward..339/217 .1 3,123,427 3/1964 Yopp ..339/252 P R25,798 6/1965 Platz...339/252 P 3,205,469 9/1965 Frank et a1 ..339/18 C 3,375,486 3/1968Clayton ..339/252 P 3,400,358 9/1968 Byrnes et al ..339/252 P 1 Oct.10,1972

3,538,491 11/1970 Longenecker et a1 ..339/256 Primary Examiner.loseph H.McGlynn v Attorney-Robert W. Beart, Michael Kovac, Jack R. Halvorsen,Thomas W. Buckman and Olson, Trexler,

Wolters & Bushnell [5 7] ABSTRACT A plug connector element having aplurality of contact arms which are configured to permit thelongitudinal edges thereof to abut upon total compression of the plugconnector, such as when associated within a complimentary socketelement, thus providing a relatively stable connection. The plugconnector element is further provided with a sleeve or ferrule portionwhich is connected to the contact arms as well as to an associatedconductor wire in such a manner as to assure penetrating engagement withthe conductor wire while maintaining continuous contact between thecontact arms and the conductor wire.

16 Claims, 26 Drawing Figures PATENTED B 10 I972 3.697.931

sum 1 UF 5 INVENTOR K an .1 Ach/en PATENTEnom 101912 3.697.931

sum 2 or 5 INVENTOR K uri J Achfen His A H 'ys PATENTEUncnomn 3,697,931sum 3 or 5 INVENTOR Kun J Ach fen His AH'ys PATENTEDUBTWIQT? 3.697.931

SHEET I; 0F 5 INVENTOR Kurt J Achfen E i l l 5 ,1 5 BY :h' I. 4/

His Auys PATENTEDBBT 1 I912 3.697.931 sum 5 or 5 INVENTOR Kurf J Aer/2fen BY h His AH'ys ELECTRICAL PLUG CONTACT BACKGROUND OF THE INVENTIONIn present day electrical equipment, it is common practice to employ pinand socket connections of relatively small configuration in highly densespacings. It is not unusual for present day electronic computer equipment to require electrical contacts spaced as close together as 0.050inches on centers.

One example of a prior art attempt to provide a contact system for usein miniature environments has been the use of twisted wire strands asthe male contact member of a plug socket system. This approach, whileadequately allowing for the proper density of contacts, is obviouslyinherently structurally instable. The use of wire strands presents arelatively flexible male plug member which is fragile and highlysusceptible to forces tending to bend it from its longitudinal axis.This construction has necessitated the use of a housing system toproperly protect the strand members when not in use.

In small environments, a plug connector member should structurallyresist bending moments which may possibly occur should the male memberbe slightly out of line with the longitudinal axis of the socket member.

Manufacturing techniques and structural configurations for theconnection of conductor wire to a plugtype contact member utilized inthe prior art relating to connectors in general, are not entirelyadequate for use in the miniature environment.

SUMMARY OF THE INVENTION Accordingly, it is the principle object of thisinvention to provide a male contact plug which will provide excellentelectrical contact with an associated socket and terminal whileinherently resisting forces tending to bend the plug member.

An advantage of this invention is the provision of a plugin connectorelement which increases in columnar strength as it is inserted in anassociated socket terminal.

Moreover, an object of this invention is to provide a plug-in connectorwhich is attached to a conductor wire in such a manner as to provide apenetrating, positive electrical contact between the connector and thewire prior to subsequent operations on the wire and ferrule whichprevent separation between the two elev ments.

A related advantage of this invention is, therefore, the provision of aferrule portion of a plug-in terminal which inherently enhances theelectrical conductivity while simultaneously protecting itself fromseparation from a conductor wire.

A related object of the invention is to provide an efficient method ofconstructing a plug-in terminal connector from sheet material.

In accordance with the invention, the above and other objects andadvantages are accomplished by a terminal connector of the plug-in typewhich includes a probe portion having a generally bullet-shape andincluding a plurality of contact arms which are slightly bowed outwardlyand which, in their relaxed position, present an outer diameter slightlylarger than the inner diameter of an associated socket terminalconnector. The contact arms are of such a width as to substantiallyradially abut one another upon compression when operatively associatedwith a mating terminal socket.

A ferrule portion is attached to a conductor wire in such a manner as topositively insure electrical contact by using a radially inwardlyextending seam means for impingement with the conductor wire. Theferrule means if further designed to accept, between conductor wire andinner surface of the ferrule, the free extending ends of the contactarms.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is an enlarged perspective viewof the plug connector of the present invention.

FIG. 2 is a perspective view, on a scale smaller than FIG. 1, of oneenvironment in which the present invention is utilized, i.e., mating pinand socket bodies.

FIG. 3 is a side elevational view of the plug connector.

FIG. 4 is a side view, partially in section, showing the plug-inconnector operatively associated with a socket connector.

FIG. 5 is an enlarged end sectional view taken along the lines 5-5 ofFIG. 3.

FIG. 6 is an enlarged end sectional view taken along the lines 6-6 inFIG. 4.

FIG. 7 is an enlarged end sectional view taken along the lines 7-7 inFIG. 4.

FIG. 8 is an enlarged end sectional view similar to that of FIG. 7 priorto final formation of the ferrule.

FIG. 9 is an enlarged fragmentary perspective view of the plug connectorprior to crimping.

FIG. 10 is a fragmentary perspective view similar to FIG. 9 showing thecontact arms after crimping.

FIG. 11 is an end sectional view taken along the lines 11-11 in FIG. 4.

FIG. 12 is a perspective view of the flat blank from which the plugconnector is formed.

FIG. I3 is a plan view of the blank after the edges of the base portionare deformed to a position generally perpendicular to the planeof thebase.

FIG. 14 is a sectional view taken along the line 14- 14 of FIG. 13.

' FIG. 15 is a plan view of the blank showing partial formation of acylindrical ferrule from the base portion of the blank.

FIG. 16 is a sectional view taken along the line 16- 16 of FIG. 15.

FIG. 17 is a plan view of the blank after formation of the bowedportions of the contact arm.

FIG. 18 is a sectional view taken along the line 18- 18 of FIG. 17.

FIG. 19 is a sectional view taken along the line I9- 19 of FIG. 17.

FIGS. 20 and 21 are perspective views of successive steps inthe assemblyof the contact following the drawing of the bullet nose.

FIG. 22 is a plan view of an alternate method of producing blanks.

FIG. 23 is a plan view of an alternate embodiment of a blank used in theformation of a connector plug.

FIG. 24 is a sectional view similar to FIG. I7 utilizing the alternateembodiment of FIG. 24.

FIG. 25 is an exploded perspective view of an alternate embodiment ofthis invention.

FIG. 26 is an enlarged perspective view of an alternate embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION Turning now to the drawings, FIG.I shows a plug-in connector with a ferrule portion 12 and a probe orcontact portion 14. The probe portion includes a tip with arms 18emanating therefrom which extend longitudinally of the axis of theconnector. At least two of the free extremities of arms 16 are shown tobe inserted in the bore of a barrel or ferrule portion 12. The ferruleportion 12 is formed from a sheet of electrically conductive material.Ferrule 12 includes a seam 22 extending longitudinal thereof. The seam22 protrudes radially inwardly of the ferrule 12 for impinging contactwith an associated conductor wire.

FIG. 2 illustrates an environment in which the connector of the presentinvention can be utilized. Electronic computer equipment and the likerequires large numbers of terminal connections within a small area andthus, pin bodies 26 and socket bodies 28 are generally utilized toachieve this density. FIG. 2 shows how a plurality of plug connectorscan be simultaneously associated with corresponding sockets housed inbody 28. This figure is meant to be illustrative of the environmentutilized and in no way meant to be restrictive as to the particularstructure necessary to accommodate the connectors of the presentinvention.

In the embodiment illustrated by FIG. 3, it is shown that the arms 16each include a generally bowed portion 18 which allows the arms to beradially spaced from one another in the uncompressed state of theconnector. Portions 18 of the arms provide a spring-like characteristicto the probe 14, effectively establishing a radially outwardly biasedcondition in the probe I4.

The plug connector 10 is normally utilized with an associated socketterminal connector 34 as shown in FIG. 4. Connector systems of theplug-in socket variety depend on surface contact between the outersurface of a plug and the inner surface of a socket to provide acompleted circuit, thus enabling current to flow from one terminal toanother. In this type of environment, constant, agressive surfacecontact between the plug and the socket is extremely desirable. Theconfiguration of the present invention provides this desired agressiveelectrical contact in addition to providing a maximum area of surfacecontact between the plug and the socket.

Referring to FIG. 5, it will be seen thatthe arms' 16 are of generallyarcuate configuration which enables substantially uniform continualcontact between the probe 14 and the socket 34 which is also generallyof a circular cross-sectional configuration.

As will be seen in FIG. 4, the probe 14 is inserted in an aperture 36 ofthe socket 34 in the normal fashion. However, it should be noted thatthe arms 16 are of such a width as to allow the edges 38 of the arms tosubstantially abut one another upon the insertion of the probe in thesocket. This substantial abutment of edges 38 with one anotheressentially transforms the probe 14 from a series of spring-like andrelativelyflexible elements 16, into a configuration which provides anelectrical connection with strong resistence to bending about itslongitudinal axis. The abutment of the edges 38 upon insertion in anassociated socket 34 produces a column effect which greatly increasesthe stability of the connection. FIG. 6 shows a cross-section of themating probe and socket members 14 and 34 respectively, and specificallyillustrates the abutment of edges 38 with one another which aids inproducing the desired stability in the connection.

The bowed portions 18, when inserted in the socket 34, are continuallyand agressively forced into surface contact with the inner periphery 40of the socket 34 as the result of the spring-like tendencies of the arms16.

Thus, it is apparent that the probe 14 provides a maximum of surfacecontact between the connector 10 and socket terminal 34 whilesignificantly increasing the stability. of the connection through theabutment of edges 38 within the socket.

The tip 20 is of a generally conical configuration, thus facilitatingthe entry of the probe .14 into the aperture 36. Once the probe 14 isinserted within the socket 34, as shown in FIG. 4, the outer diameter ofthe probe is substantially equal to the inner diameter of the socket 34.However, as a result of the springlike tendencies of the arms 16, theouter diameter of the probe, in an uncompressed condition, as showngenerally in FIG. 5, is of a larger diameter than the inner diameter ofan associated socket 34.

It should be understood that this invention must operate within therange of tolerances necessary in the construction of the variouselements. For this reason, the arms 16 are shown slightly spacedradially from one another a distance 74 in FIG. 1. Without such spacing,the connector would present a binding interference fit in an associatedsocket 34, if the socket is on the low side of an acceptable tolerancerange or if the arms 16 are on the high side of an acceptable tolerancerange. FIG. 4 shows actual abutment between edges 38. This configurationwill exist if the dimensions of the arms 16 or aperture 36 approach thelimits of the tolerance variations discussed above. In other situations,within the manufacturing tolerances of the various members, the arms 16will be slightly spaced apart upon compression. This slight spacing willnot prevent the probe from providing a substantial column effect andsubstantial stability to the connector.

The present invention discloses the use of three arms 16 in a probe andthe width of each arm 16 may be approximately one-third the innerdiameter of its associated socket terminal. This dimensionalrelationship will provide a columnar configuration upon the compressionof the probe as shown in FIG. 4 and 6. Should a different number of armsbe utilized in a probe, the columnar configuration can still be achievedby relating the inner periphery P of a socket connector with a number Nof contact arms such that the width of the arms approximate P/N.

The present invention is also concerned with providing a terminalplug-in connector which insures positive contact between a probe and theterminal end of an associated conductor wire. Thus, in the presentembodiment shown in FIG. 9, the free extending extremities 42 of thecontact arms 16 are shown to extend longitudinally within a sleeve orferrule portion 12. These free extremities are also preferably of aconcave configuration similar to that shown in FIG. 5, thus increasingthe surface contact area between the conductor wire 46, the contact arm16 and the inner surface of the electrically conductive ferrule 12. Itis seen from FIG. 9 that current is capable of flowing from theconductor wire 46 to the probe 14 through substantial surface contactbetween the conductor 46 and the extremities 42.

While various means and methods may be utilized to connect the ferrulewith the probe of the present invention, e.g., soldering, crimping,etc., it may be desirable to provide further features to insure propercarrying of current from the conductor 46 to the probe 14. Crimpingsections 24, shown in FIG. I and FIG. 11, are utilized to substantiallyincrease metal to metal contact between the conductor wire 46 and theferrule 12. FIG. II shows how the crimp section 24 substantiallydecreases the cross-sectional area in which the conductor 46 is confinedand thus continuously forces surface contact between the ferrule 12 andthe conductor wire 46. The free extending extremities 42 are preferablysimultaneously deformed as the ferrule obtains it crimpted section 24.FIG. described the crimped areas 50 which are associated with thecrimped sections 24 of the ferrule 12. Thus, it is apparent that thefree extending extremities 42 effectively increase the electricalsurface contact between the probe 14 and the conductor 46 while at thesame time provide a mechanical interlock between the ferrule 12, probe14 and a conductor 46. The step configuration formed by crimped areas 50effectively precludes axial separation between the associated elementsof the plug-in terminal connector.

As a further feature of the present invention, the ferrule portion 12 isconstructed in such a manner as to insure a penetrating contact betweenthe conductor 46 and the ferrule 12. As shown in FIG. 1, generally, andin FIGS. 7 and 8 more specifically, the ferrule 12 is provided with aseam 22. This seam 22 is formed by turning the longitudinal edges 23, ofthe blank from which the ferrule 12 is formed, in such a manner as toextend radially inwardly of the ferrule. As shown in FIG. 7, this seam22 penetrates the conductor wire 46 in an impingement area 48 and thusfurther increases the electrical contact between the conductor wire 46and the connector 10 generally. This impingement acts to preventrelative rotational motion between the conductor 46 and the ferrule 12.The very nature of the impingement of the seam 22 with the wire 46 tendsto exert forces on the longitudinal edges 23 in such a manner as tocontinually .force these edges in a juxtaposed position, thus retainingthe seam configuration. The tendency of the conductor wire 46 to retainthe seam 22 in a closed position thus enhances the structural integrityof the ferrule 12. The seam 22 therefore aids in fulfilling bothstructural and electrical requirements of the ferrule 12.

In the preferred construction of the invention three arms 16 emanatefrom a central conical tip and extend longitudinally of the conductoraxis; however, any desired number of arms may be used. Two of these arms18 have free extending extremities which are received in the ferrule 12between the conductor wire 46 and the inner surface 41 of the ferrule.The remaining arm is integrally connected to the ferrule 12 forming aone-piece connector body. This one-piece construction further reducesthe possibility of intermittent current flow since the probe 14 andferrule 12 are not discrete members and do not necessarily requireconductive contact between arms 42 and ferrule 12.

The present invention is also concerned with a method of forming aplug-in connector having the above mentioned characteristics.Accordingly, FIG. 12 shows a one-piece blank 52 from which the connector10 is constructed in a dieformingoperation. The blank 52 is of agenerally thin electrically conductive material. Material such asberylium-copper, or the like, has been found to be generally well suitedfor use in the contemplated environment. The blank shown utilizespositioning holes 54 in a carrier strip 82 for advancement of the blankmaterial to the appropriate die station. The working portions of theblank 52 generally may be described as a rectangular base portion 58 andan integrally connected star-shaped portion 60. The star-shaped portionincludes a central portion 56 and radially spaced arms 16 emanatingtherefrom. One of such arms 16 being connected to the base portion 58generally along the longitudinal centerline thereof.

Referring now to FIG. 13, the longitudinal edges 23 are shown to bedeformed to a position generally perpendicular to the plane of the baseportion of the blank 58. This positioning is amplified in the sectionalview of FIG. 14.

FIG. 15 discloses the rolling or partial forming of the barrel-likeconfiguration for the ferrule portion 12.

' FIG. 16, a sectional view through the base portion 58,

is somewhat similar to the view of FIG. 8 which shows the partiallyformed configuration of the connector. Both FIGS. 8 and 16 show thelongitudinal edges 23 which ultimately are to form the seam 22.

FIG. 17 generally shows the initial operation on the star-shaped portionof the blank 60. The central portion 56 and adjacent portions of. thearms 16 are deformed downwardly, from a predetermined die plane A, intothe general configuration shown in FIG. 18. The lower level 68,ultimately forms the bowed portions I8 of the connector as shown in FIG.9. The portions of the star-shaped blank 60 which remain along the dieplane A are the free extending extremities 42 of the probe 14, also asshown in FIG. 9. The formation of two levels, as in FIG. 18 alsoincludes the formation of the arms 16 into an arcuate cross-sectionalconfiguration. This is shown more specifically in FIG. 19.

FIG. 20 shows the general shape of the blank after drawing and formingthe bullet-shaped conical tip from the central portion 56. The drawingis accomplished by appropriate mating dies. The blank 52 has nowgenerally assumed the bullet-shaped configuration described above inrelation to the connector 10. It should be noted that in actual practicethe blank 52 may be progressively deformed through the stages of FIGS.13 through 20 without moving from station to station. This has beenfound to be most efficient when producing miniature parts of the typedescribed.

FIGS. 20 and 21 illustrate the final stages of assembly of the connector10 to an associated terminal wire 46. In FIG. 20, the free extendingarms are positioned in a generally coplanar relationship prior to finalpreassembly with the ferrule portion 12. In FIG. 21, the free extendingextremities 42 are clipped in and retained behind longitudinal edges 23.Thus, it is apparent that the deformed edges 23, which ultimately formthe impinging seam 22, also act to retain the ferrule 12 and associatedarms 16 in a semi-assembled position immediately prior to final assemblywith an associated conductor wire 46. This semi-assembled conditionreduces the handling problems which are inherently present inconstructing elements of the size contemplated by this invention.

The blank 52 may be advantageously deformed to present a lip or shoulderportion 70 which will allow easy separation, by an appropriate cuttingtool, from the scrap material. The connector may be retained on thecarrier strip to assist in connecting the wire to the ferrule. After theconnection, the shoulder portion 70 may be severed from the strip 82.

The above method may be utilized to produce connectors from a singlesheet of conductive material which are all oriented in one direction.However, an alternate embodiment of this invention is shown in FIG. 22.Blank 62 describes an alternating blanking procedure which is anefficient utilization of the stock material. After the initial formationof the star portion 60a and the base portion 58a of the blank, theformation of the connector may be accomplished in a manner similar tothat described above.

Also contemplated in the invention, is an alternate embodiment of thebasic blank 52. The embodiment shown in FIG. 23 includes tabs 64 and 66on the free extending extremities of the arms 16. These tabs are of awidth greater than the width of the bowed portions 18.

FIG. 24 is similar to FIG. 7 and shows the use of these tab portions 64and 66 in a completed connector. Referring back to FIG. 7 it is seenthat due to the integral connection of one of the arms 16 to the ferrule12, only two free extending extremities are present between theconductor wire 46 and the inner periphery 41 of the ferrule. This leavesa void 72 into which a conductor wire 46 may be forced, possiblyallowing intermittent non-continuous contact between the conductor andthe ferrule 12 or probe 14. However, as shown in FIG. 24, this void areais eliminated through the use of tabs 64 and 66. Thus, it is possible toaccommodate smaller diameters of conductor wire in essentially the sameconnector without appreciably changing the dimensions of the blank. Thetabs 64 and 66 will also provide more surface contact between theconductor. wire 46 and the probe 14. A ferrule having an inner peripheryP1 can thus obtain a uniform surface contact and reduction incross-sectional area within the ferrule, by expanding the width of thefree extending arms 42 to a width of approximately Pl (Nl), where N isthe number of arms 16 in the contact probe.

While the invention has been described above as a one-pieceferrule-probe combination, it is anticipated that the connector could beformed from two discrete members. FIG. 25 shows an alternate embodimentof the invention in which ferrule 12a and probe 14a are separateelements not integrally connected through one of the arms 16, as showngenerally by the blank in FIG. 12. The ferrule 12a could receive theextending extremities of all arms 16a and further receive a conductor46a in a manner similar to that described with respect to the preferredembodiment above. The elements 14a and 12a could then be restrained fromaxial separation through the crimping procedure described relative toFIGS. 10 and 11.

It is also envisioned that the connector can be manufactured having onlytwo arms. The embodiment shown in FIG. 26 includes a ferrule 12b with aprobe 14b. The probe has two arms 16b configured similar to the arms 16described above. This two-armed connector is capable of forming arelatively rigid electrical connection by utilizing a plurality of tabs80 which extend substantially normal to their associated arm 16b in sucha manner as to allow each tab 80 to be in alignment for abutment with asimilar tab on the other arm 16b. This configuration will providesubstantial abutment of the contact arms when the probe 14b iscompressed in an associated socket connector.

Thus it is apparent that there has been provided, in accordance with theinvention, a plug-in connector which insures continuous currentflowbetween terminal wires to be connected, especially in miniatureenvironments. The connector described above utilizes a probe whichincludes contact arms designed specifically to provide continuallybiased electrical contact with an associated socket terminal while atthe same time substantially increases the stability of the connection byforming a column-like member upon insertion in the associated socket.The connector in the present invention further provides a ferruleportion which aids in the preassembly of the probe and which insures apenetrating positive electrical contact between itself and an associatedconductor wire. The structure relating to the above described inventionalso provides a connector which has a relatively long life due to thespring-like tendencies of its contact arms and a novel associationbetween a probe member and the ferrule member which substantiallyreduces the possibility of axial separation of the two.

While the invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives,modifications, and variations will be apparent to those skilled in theart in light of the foregoing description. Accordingly, it is intendedto embrace all such alternatives, modifications and variations as fallwithin'the spirit and broad scope of the intended claims.

lclaim:

l. A one-piece plug connector formed from sheet material comprising asleeve and a contact portion, the contact portion comprising abullet-nose tip with a plurality of arms emanating therefrom andextending generally longitudinally behind the tip,'one arm injacent armsto substantially abut and form a columnar structure upon compression ofthe contact portion, wherein the connector is capable of sustainingelectrical contact with a mating socket portion while resisting bendingof the contact portion.

2. A connector in accordance with claim 1 wherein the plurality of armsincludes a portion adjacent the tip having a first width which allowsabutment of the longitudinal edges upon radial compression of the arms,the remaining arms including a portion received in the sleeve having asecond width which is greater than the first width.

3. A connector in accordance with claim 2 wherein the sleeve includes aseam means extending longitudinal and protruding radially inwardlythereof for impinging contact with an associated conductor wire.

4. A one-piece plug connector for association with a mating socketconnector including a probe portion and a barrel portion, the probeportion having a bullet-nose tip and a plurality of longitudinallyextending contact arms emanating therefrom, said contact arms comprisingat least one free extending arm and one arm integrally attached to thebarrel portion, each contact arm including outwardly bowed portions foraggressive mating contact with an associated socket, the bowed portionsbeing of such a width as to allow the edges of the contact arms tosubstantially abut when the probe is in compressed condition, therebyimparting columnar strength to the probe upon insertion in the matingsocket, the free extending arms extending into the barrel portion andhaving a width greater than the width of their associated bowed portionsto uniformly decrease the cross-sectional area within the barrel, thebarrel including seam means extending radially inwardly and situatedbetween two of the free extending arms, whereby an associated conductoris positioned in the barrel in such a manner as to be impinged by theseam means and operatively connected to the contact arms through boththe barrel and free extending arms.

5. A one-piece plug connector in accordance with claim 4 for associationwith a mating socket having a contact surface with an inner periphery P,the probe portion having N number of contact arms each having a width ofapproximately P/N, said contact arms being radially spaced from oneanother in their non-compressed state, the barrel portion having aninner periphery P1, and the free extending arms having a width ofapproximately P1 (Nl).

6. In a connector plug for a conductor terminal, contact means andferrule means formed in one-piece from a sheet of conductive material,the contact means including three arms emanating from a centralconicaltipped portion and folded back to be received in the bore of theferrule, one of said arms integrally connected to the ferrule, each armbeing bowed outwardly from the longitudinal axis of the plug to providea resiliently biased electrical contact with a cooperating socketconnector, the ferrule means including inwardly extending seam meansimpinging an associated conductor thus affording positive electricalcontact while retaining the ferrule in a closed configuration, the twofree arms extending into the ferrule for operative association betweenthe ferrule and conductor and straddling the inwardly extending seam.

7. in an electrical connection of the plug and socket type, a contactprobe including longitudinally extending means for providing agressive,substantially constant electrical contact with an associated socketwhile substantially increasing the column strength of the probe uponinsertion in an associated socket, a conductive sleeve means forconnecting an associated conductor to the contact probe, said sleevemeans formed from sheet material and including a longitudinal seamformed from edges of the sheet material, said seam extending radiallyinwardly for impingement into the associated conductor, said probeincluding a conical shaped tip at one end for facilitating entry of theplug into a socket, the other end of the probe including a plurality ofarms inserted in the sleeve and positioned between the conductor and theinner surface of the sleeve, said sleeve and associated arms includingat least one crimped section for increasing the electrical contactbetween the conductor, probe, and sleeve as well as preventing relativeaxial movement between the conductor, probe, and sleeve.

8. An electrical connection as set forth in claim 7 wherein the armshave a generally arcuate cross-section for increasing the surfacecontact of the arms between the sleeve and conductor.

9. A plug-in connector as set forth in claim 8 wherein the free ends oftwo contact arms are positioned between the conductor wire and the innersurface of the ferrule portion thus providing substantial surfacecontact between the conductor, ferrule, and contact portions.

10. A plug-in connector for electrically connecting the terminal ends ofa conductor with a cooperating socket connector, including contact meansand a ferrule portion, the contact means being of a generallybullet-like configuration including a plurality of arms integrallyconnected to a generally conical shaped tip portion, at least one ofsaid arms being integrally connected to said ferrule portion, said armshaving portions bowed outwardly from the longitudinal axis of thecontact means, the bowed portions forming a biased electrical engagementbetween the contact means and an associated socket connector, said armsbeing of sufficient width and being spaced radially from one another sothat the longitudinal edges of the arms substantially abut whenoperatively associated with a socket connector, the ferrule portionreceiving an end of a conductor wire and further receiving free ends ofthe arms of the contact means with the conductor wire, whereby thecontact means provides a radially biased contact with a socket connectorwhile providing a connection which has relatively large column strength.

11. A plug connector, comprising a sleeve having a contact portionextending outwardly from one end thereof, the sleeve and contact portionformed from electrically conductive sheet materials, said sleeveincluding a formed seam means extending radially inwardly forming apenetrating contact with an associated conductor wire, the contactportion including a nose with a plurality of longitudinally extendingarms emanating therefrom, the arms having portions bowed outwardly fromthe longitudinal axis of the contact portion and radially spaced fromeach other, the free ends of the arms received in the sleeve forelectrical contact between the sleeve, arms and conductor, said sleeveincluding at least one crimped portion for insuring contact between thesleeve and conductor, the portions of the contact arms received in thesleeve also including crimped sections which generally eliminaterelative axial movement between the sleeve and arms.

12. The method of making a one-piece plug connector comprising steps ofstamping from a sheet of conductive material a blank having a generallyrectangular base portion and a generally star-shaped portion having aplurality of arms emanating from a central, generally circular portion,one of said arms integrally connected to the base portion, turning thelongitudinal edges of the rectangular base portion to a positiongenerally perpendicular to the plane of the base portion, folding thebase portion to a generally U-shaped cross-sectional configuration,deforming the star-shaped portion into a bullet-shaped configurationwith the center of the circular portion becoming the tip of thebullet-shaped configuration, while slightly bowing the portions of thearms nearest the tip portion, pushing the free extending arms into thebase portion behind the longitudinal edges, inserting a conductor wireinto the base portion, and closing the base portion to form a barrelaround the wire and free extending arms.

13. The method of making a one-piece plug connector in accordance withclaim 12 wherein the bulletshaped configuration having slightly bowedarms is formed by depressing the circular portion and portions of thearms connected to the circular portion to a lower horizontal plane thanthe remainder of the blank, and drawing the lower plane portion into abullet-shaped configuration with the circular portion being of agenerally conical configuration.

14. The method of making a one-piece plug connector in accordance withclaim 13 wherein the plurality of .arms are formed of a predeterminedwidth and the free extending arms are formed with an outer extremityportion of a larger width than the generally bowed portions of the arms.

15. The method of making a one-piece plug connector in accordance withclaim 13 including locking the free extending arm inside the Ushapedbase portion adjacent the longitudinal edges of the base portion,closing the U-shaped base portion while impinging the longitudinal edgesof the base portion into the associated conductor wire, crimping thebase portion while deforming portions of the free extending armsinwardly thus impinging the conductor with both a portion of the surfaceof the base portion as well as portions of the free extending arms.

16. The method of making a one-piece plug connector in accordance withclaim 13 including forming the arms with a curved cross-sectionalconfiguration.

1. A one-piece plug connector formed from sheet material comprising asleeve and a contact portion, the contact portion comprising abullet-nose tip with a plurality of arms emanating therefrom andextending generally longitudinally behind the tip, one arm integrallyconnected to the sleeve and the free ends of the remaining arms beingreceived in the sleeve, said arms including radially outwardly biasingmeans for generally resisting radial compression of the contact portionwhile allowing the longitudinal edges of the adjacent arms tosubstantially abut and form a columnar structure upon compression of thecontact portion, wherein the connector is capable of sustainingelectrical contact with a mating socket portion while resisting bendingof the contact portion.
 2. A connector in accordance with claim 1wherein the plurality of arms includes a portion adjacent the tip havinga first width which allows abutment of the longitudinal edges uponradial compression of the arms, the remaining arms including a portionreceived in the sleeve having a second width which is greater than thefirst width.
 3. A connector in accordance with claim 2 wherein thesleeve includes a seam means extending longitudinal and protrudingradially inwardly thereof for impinging contact with an associatedconductor wire.
 4. A one-piece plug connector for association with amating socket connector including a probe portion and a barrel portion,the probe portion having a bullet-nose tip and a plUrality oflongitudinally extending contact arms emanating therefrom, said contactarms comprising at least one free extending arm and one arm integrallyattached to the barrel portion, each contact arm including outwardlybowed portions for aggressive mating contact with an associated socket,the bowed portions being of such a width as to allow the edges of thecontact arms to substantially abut when the probe is in compressedcondition, thereby imparting columnar strength to the probe uponinsertion in the mating socket, the free extending arms extending intothe barrel portion and having a width greater than the width of theirassociated bowed portions to uniformly decrease the cross-sectional areawithin the barrel, the barrel including seam means extending radiallyinwardly and situated between two of the free extending arms, whereby anassociated conductor is positioned in the barrel in such a manner as tobe impinged by the seam means and operatively connected to the contactarms through both the barrel and free extending arms.
 5. A one-pieceplug connector in accordance with claim 4 for association with a matingsocket having a contact surface with an inner periphery P, the probeportion having N number of contact arms each having a width ofapproximately P/N, said contact arms being radially spaced from oneanother in their non-compressed state, the barrel portion having aninner periphery P1, and the free extending arms having a width ofapproximately P1 (N-1).
 6. In a connector plug for a conductor terminal,contact means and ferrule means formed in one-piece from a sheet ofconductive material, the contact means including three arms emanatingfrom a central conical-tipped portion and folded back to be received inthe bore of the ferrule, one of said arms integrally connected to theferrule, each arm being bowed outwardly from the longitudinal axis ofthe plug to provide a resiliently biased electrical contact with acooperating socket connector, the ferrule means including inwardlyextending seam means impinging an associated conductor thus affordingpositive electrical contact while retaining the ferrule in a closedconfiguration, the two free arms extending into the ferrule foroperative association between the ferrule and conductor and straddlingthe inwardly extending seam.
 7. In an electrical connection of the plugand socket type, a contact probe including longitudinally extendingmeans for providing agressive, substantially constant electrical contactwith an associated socket while substantially increasing the columnstrength of the probe upon insertion in an associated socket, aconductive sleeve means for connecting an associated conductor to thecontact probe, said sleeve means formed from sheet material andincluding a longitudinal seam formed from edges of the sheet material,said seam extending radially inwardly for impingement into theassociated conductor, said probe including a conical shaped tip at oneend for facilitating entry of the plug into a socket, the other end ofthe probe including a plurality of arms inserted in the sleeve andpositioned between the conductor and the inner surface of the sleeve,said sleeve and associated arms including at least one crimped sectionfor increasing the electrical contact between the conductor, probe, andsleeve as well as preventing relative axial movement between theconductor, probe, and sleeve.
 8. An electrical connection as set forthin claim 7 wherein the arms have a generally arcuate cross-section forincreasing the surface contact of the arms between the sleeve andconductor.
 9. A plug-in connector as set forth in claim 8 wherein thefree ends of two contact arms are positioned between the conductor wireand the inner surface of the ferrule portion thus providing substantialsurface contact between the conductor, ferrule, and contact portions.10. A plug-in connector for electrically connecting the terminal ends ofa conductor with a cooperating socket connector, inclUding contact meansand a ferrule portion, the contact means being of a generallybullet-like configuration including a plurality of arms integrallyconnected to a generally conical shaped tip portion, at least one ofsaid arms being integrally connected to said ferrule portion, said armshaving portions bowed outwardly from the longitudinal axis of thecontact means, the bowed portions forming a biased electrical engagementbetween the contact means and an associated socket connector, said armsbeing of sufficient width and being spaced radially from one another sothat the longitudinal edges of the arms substantially abut whenoperatively associated with a socket connector, the ferrule portionreceiving an end of a conductor wire and further receiving free ends ofthe arms of the contact means with the conductor wire, whereby thecontact means provides a radially biased contact with a socket connectorwhile providing a connection which has relatively large column strength.11. A plug connector, comprising a sleeve having a contact portionextending outwardly from one end thereof, the sleeve and contact portionformed from electrically conductive sheet materials, said sleeveincluding a formed seam means extending radially inwardly forming apenetrating contact with an associated conductor wire, the contactportion including a nose with a plurality of longitudinally extendingarms emanating therefrom, the arms having portions bowed outwardly fromthe longitudinal axis of the contact portion and radially spaced fromeach other, the free ends of the arms received in the sleeve forelectrical contact between the sleeve, arms and conductor, said sleeveincluding at least one crimped portion for insuring contact between thesleeve and conductor, the portions of the contact arms received in thesleeve also including crimped sections which generally eliminaterelative axial movement between the sleeve and arms.
 12. The method ofmaking a one-piece plug connector comprising steps of stamping from asheet of conductive material a blank having a generally rectangular baseportion and a generally star-shaped portion having a plurality of armsemanating from a central, generally circular portion, one of said armsintegrally connected to the base portion, turning the longitudinal edgesof the rectangular base portion to a position generally perpendicular tothe plane of the base portion, folding the base portion to a generallyU-shaped cross-sectional configuration, deforming the star-shapedportion into a bullet-shaped configuration with the center of thecircular portion becoming the tip of the bullet-shaped configuration,while slightly bowing the portions of the arms nearest the tip portion,pushing the free extending arms into the base portion behind thelongitudinal edges, inserting a conductor wire into the base portion,and closing the base portion to form a barrel around the wire and freeextending arms.
 13. The method of making a one-piece plug connector inaccordance with claim 12 wherein the bullet-shaped configuration havingslightly bowed arms is formed by depressing the circular portion andportions of the arms connected to the circular portion to a lowerhorizontal plane than the remainder of the blank, and drawing the lowerplane portion into a bullet-shaped configuration with the circularportion being of a generally conical configuration.
 14. The method ofmaking a one-piece plug connector in accordance with claim 13 whereinthe plurality of arms are formed of a predetermined width and the freeextending arms are formed with an outer extremity portion of a largerwidth than the generally bowed portions of the arms.
 15. The method ofmaking a one-piece plug connector in accordance with claim 13 includinglocking the free extending arm inside the U-shaped base portion adjacentthe longitudinal edges of the base portion, closing the U-shaped baseportion while impinging the longitudinal edges of the base portion intothe associated conductor wire, crimping The base portion while deformingportions of the free extending arms inwardly thus impinging theconductor with both a portion of the surface of the base portion as wellas portions of the free extending arms.
 16. The method of making aone-piece plug connector in accordance with claim 13 including formingthe arms with a curved cross-sectional configuration.